AU2007231769B2 - Wall box mounting - Google Patents

Abstract

A wall box for mounting within a recess in a wall is disclosed. The wall box has on at least one side, at least one tab which can be bent outwards to provide a mounting surface to secure the wall box to the wall or a support associated with the wall. The 5 wall box can also have a plurality of tabs set at different levels on the sides of the wall box to facilitate mounting of the wall box at different depths and/or allow different mounting systems, including the use of an additional wall surface.

Description

Regulation 3.2 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: Clipsal Australia Pty Ltd Actual Inventor: Kenneth Basil Gransbury Address for Service: C/- MADDERNS, 1st Floor, 64 Hindmarsh Square, Adelaide, South Australia, Australia Invention title: WALL BOX MOUNTING Details of Associated Provisional Application No: 2006906065 dated 1 November 2006 The following statement is a full description of this invention, including the best method of performing it known to us. PatAU131} TECHNICAL FIELD The present invention relates to wall boxes and the mounting of wall boxes to or within a wall. 5 PRIORITY The present application claims priority from Australian Provisional Patent Application No. 2006906065 entitled "Wall Box Mounting". The entire content of this provisional application is hereby incorporated by reference. 0 BACKGROUND Boxes used to house equipment or electrical machinery or elements are often mounted to or within a wall for easy access and convenience. 5 There are various methods of mounting the wall box to the wall, including nailing the wall box directly to the wall through the sides of the wall box. An alternative method is to use brackets which are attached to the wall box during the installation procedure and then secured to the wall. 0 Current methods and apparatus require that the installer store and carry several different pieces of equipment in installing a wall box, such as the wall box itself, enough brackets to mount the wall box, and other attachment means such as screws or bolts. As well as being inconvenient, the requirement to attach numerous pieces to install the wall box increases the time required for installation, thus increasing costs. 25 It is an object of the present invention to provide an apparatus and method to facilitate the installation of a wall box. SUMMARY OF THE INVENTION 30 According to a first aspect of the present invention, there is provided a wall box including a plurality of sides defining a front and a back, wherein at least one of the plurality of sides includes an integral tab portion located within the boundary of the 2 respective side which in use, is able to be bent outwards to provide a mounting surface for mounting to a support. In one form, at least two sides have at least one integral tab portion. 5 In another form, all sides have at least one tab portion. In a further form, at least one side has a plurality of integral tab portions. 0 In yet a further form, the plurality of integral tab portions are disposed at different depths on the at least one side. In a further form, the plurality of integral tab portions are arranged in a plurality of sets of integral tab portions, each set comprising one or more integral tab portions 5 each located within the boundary of the respective side and each set being disposed at a different depth of the at least one of the plurality of sides. According to a second aspect of the present invention, there is provided a method of mounting a wall box according to the first aspect to a wall, the method including 0 bending at least one of the integral tab portions outwards to provide a mounting surface, and securing the mounting surface to a support associated with the wall. In one form, the support associated with the wall is a stud. 25 In another form, the support associated with the wall is the wall. In a further form, the method includes determining a mounting depth at which the wall box will be mounted within the wall; selecting at least one integral tab portion disposed at an appropriate depth for the determined mounting depth; bending the 30 selected at least one integral tab portion outwards to provide the mounting surface; and securing the mounting surface to a support associated with the wall. 3 FIGURES Various aspects of the present invention will now be described in detail with reference to the following figures in which: Figure 1 - shows a wall box having an integral tab portion according to one aspect of 5 the present invention; Figure 2 - shows the wall box of Figure 1 with the integral tab portion bent outwards; Figure 3 - shows a wall box having two tab portions on two sides; Figure 4 - shows the wall box of Figure 3 with the tab portions bent outwards; 0 Figure 5 - shows the wall box of Figure 4 mounted to a wall; Figure 6 - shows a wall box with tab portions on all sides of the wall box; Figure 7 - shows a wall box with two sets of tab portions at different depths of the side; Figure 8A - shows the wall box if Figure 7 with the lower set of tab portions bent 5 outwards; Figure 8B - shows the wall box of Figure 8A mounted to a wall; Figure 8C - shows a cross-sectional side view of Figure 8B; Figure 9A - shows the wall box of Figure 7 with the upper set of tab portions bent outwards; 0 Figure 9B - shows the wall box of Figure 9A mounted to a wall; Figure 9C - shows a cross-sectional side view of Figure 9B; Figure 10A - shows an application of one aspect of the invention to a 'first fix' method; Figure 1OB - shows an application of another aspect of the invention to a 'second fix' 25 method; Figure 10C - shows the use of an escutcheon to an installed wall box; Figure 11 - shows a top cross-sectional view of the wall box mounted using both the 'first fix' and the 'second fix' methods; Figure 12 - shows an alternative form of the present invention in which the tabs bend 30 about a different axis; and Figure 13 - shows a wall box with three sets of tab portions disposed at different depths of the side. 4 Figure 14 - shows an example of possible electrical safety requirements to of a wall mounted unit; Figure 15A - shows the required width requirement of the studwork for flush mounting a wall box; 5 Figure 15B - shows the position of cables; Figure 15C - shows the position of the power cable when run through the bottom of the wall box; Figure 16 - shows a method of bending a tab away from the perimeter of the wall box; [0 Figure 17 - shows an example of a method to fit screws into the framework to position the wall box; Figure 18 - shows for one embodiment of the invention an example of the dimensions of plasterboard requiring removal for installing a flush mounted wall box; 15 Figure 19 - shows a method of bending a tab away from the perimeter of the wall box; Figure 20 - shows an example of a technique to insert the flush mounted wall box by first inserting the co-axial, data and telephone cabling; Figure 21 - shows a further step of the previous example of the technique to insert 20 the flush mounted wall box inserting secondly the power cabling; Figure 22 - shows an example of a method to fit screws into the framework to position the wall box; Figure 23 - shows an example of a method to fit the keystones; Figure 24 - shows an example of a method to remove the form in the escutcheon; 25 Figure 25 - shows an example of a method to bend up the lock tab on the escutcheon; Figure 26 - shows an example of a method to remove paint masking disks. 4a DETAILED DESCRIPTION Various aspects of the present invention will be described in the context of an electrical housing wall box, such as a patch panel. It will be understood however, that the various aspects of the invention are equally applicable to any type of wall 5 box, including but not limited to, an electricity meter, a gas meter, a circuit breaker, a fire hose housing and first aid kit box. It will also be understood that in describing the wall box being mounted to a wall, this will encompass mounting the wall box to the surface of the wall or within a 0 cavity in the wall, and will also be understood to encompass direct mounting to the wall itself, or to a support associated with the wall, such as a beam, strut or gypsum. Referring now to Figure 1, there is shown wall box 10 having side walls 11,12,13 and 14. Some wall boxes may be closed or partially closed with a back 15 and may have a 5 cover or door (not shown) to close the front. In some applications, back 15 may have one or more openings (not shown) for receiving electrical wiring or conduits such as plumbing or gas pipes for example. According to one aspect of the invention, at least one side 12 has an integral tab .0 portion 20 defined therein. Tab portion 20 may be formed by creating a space 30 in side 12 to separate tab 20 from side 12 on 3 sides, leaving a fourth side connected to side 12. This connection may remain whole, or be partially perforated, or otherwise weakened to facilitate bending as will be described in more detail further below. Of course, if the material from which wall box 10 is made is sufficiently soft or otherwise 25 bendable, no weakening will be required. It will be appreciated that while tab 20 is shown as a rectangular portion, tab 20 may be formed into any suitable shape including triangular, circular or any other regular or irregular shape. It will also be appreciated that space 30 need not be significant 30 only sufficient to allow tab portion 20 to be separated from side 12. In fact, it is within the scope of the invention that space 30 be provided as a series of small apertures or perforations to allow easy 'tearing' or other separation of tab 20 from side 12. 5 An advantage of having space 30 larger is that it may facilitate the bending of tab portion 20 away from side 12 by insertion of a tool such as a screwdriver head. Alternatively, tab portion 20 may be bent simply by manual application of pressure 5 on either side of tab portion 20 by a finger for example. In some embodiments, tab portion 20 may also have an aperture 21 for receiving a fastener such as a screw or bolt when box 10 is being installed. 0 In some embodiments, only side 12 may have a tab portion 20, however, in other embodiments, other sides, such as side 14 as shown in Figure 1, may have its own tab portion 20'. Figure 2 shows the box 10 of Figure 1, but with tab portions 20 and 20' (not visible in 5 this view) in walls 12 and 14 respectively, bent out to provide a mounting surface to allow tab 20 and therefore wall box 10, to be mounted to the wall. Wall box 10 may be secured to a wall by securing the mounting surface to a support associated with the wall, via screws, bolts, adhesives, welding, or any other suitable means as will be known to the person skilled in the art. .0 Figure 2 shows corresponding tab portion 20' (not visible in this view) in side 14 also bent outwards to provide for securement to the support. It is also conceivable that tab portion 20 could be bent inwards, into wall box 10 to 25 provide the mounting surface, if appropriate supports exist that may enter wall box 10. It will also be appreciated that tab portion 20 could be partially bent so as to provide an angled mounting surface for securement to an angled support if necessary. 30 Figure 3 shows a similar wall box 10 to that shown in Figure 2, with like elements accordingly numbered, except that in this case, side 12 has two tab portions 20a and 6 20b, with corresponding open spaces 30a and 30b. In this embodiment, opposite side 14 also has corresponding tab portions 20a' and 20b'. Figure 4 shows the wall box with tab portions 20a and 20b bent outwards. 5 Corresponding tab portions 20a' and 20b' of side 14 are also bent outwards and are not visible in this view. Figure 5 shows wall box 10 installed in a wall 40. In this example, wall box 10 is recessed in an aperture (not visible) in wall 40, and is recessed to the depth of tab 0 portions 20a, 20b, 20a' and 20b'. In this position, the tab portions can be secured to the wall by screws or the like through apertures 21a, 21b, 21a' and 21b'. Alternatively, the tab portions can be secured to wall 40 by adhesive or other means. In one form, the tab portions can be secured to a beam or strut or other support .5 within the wall 40. A covering such as gypsum, plaster, board or tiles can optionally be used on top of wall surface 40 as shown in Figure 5 to cover the tab portions and provide a flush finish between the completed wall and the opening to wall box 10. Figure 6 shows wall box 10 as shown in Figure 3 with additional tab portions 20c and !0 20c' in sides 13 and 11 respectively, which may be used for additional securement. It will be appreciated that while numerous tab portions may be provided, not all need to be deployed or used, and can remain 'closed" and unused, at the discretion of the installer. 25 In one example, one side 14 of wall box 10 may be located against a beam or strut and a nail or screw may simply be passed through aperture 21 or through side 14 itself to secure that part of wall box 10. Tab portions 20a and 20b on side 12 may be deployed to secure wall box 10 against a front face of a beam, strut, wall or other support. 30 According to another aspect of the present invention, there may be provided a plurality of sets of tab portions, each set being disposed at a different depth on side 7 12 for example. Figure 7 shows this arrangement, in which tab portions 20a and 20d form a first set, disposed closer to the bottom of wall box 10, while tab portions 20b and 20c form a second set, being disposed at a higher level than the first set. Corresponding tab portions 20a', 20d' 20b' and 20c' are also provided in this example 5 on opposite side 14. Again, corresponding sets could also be provided on one or more of sides 11 and 12 as described with reference to Figure 6. The provision of multi-levelled sets of tab portions allows the installer to vary the mounting depth at which wall box 10 is set into wall 40 as will now be described 0 with reference to Figures 8A to 9C. Figure 8A shows wall box 10 of Figure 7, with tab portions 20a, 20d and 20a', 20b' bent outwards, providing a mounting surface closer to the bottom of wall box 10. In Figure 8B, it can be seen that by selection of this set of tab portions, wall box 10 will 5 only be recessed into wall 40 at the level of these tab portions. Tab portions 20b and 20c can be seen to have been left in their original positions in side 12, as are corresponding tab portions 20b' and 20c' in side 14. Figure 8C shows a cross sectional side view of Figure 8B, showing wall box 10 partly .0 recessed into wall 40. Tab portions 20a and 20d are bent outwards to provide the mounting surfaces. Bent tab portions leave behind larger apertures 30a and 30d as seen in Figure 8C. Tab portions 20b and 20c are unchanged. In Figure 9A, the set defined by tab portions 20b and 20c is this time selected to be 25 deployed, leaving tab portions 20a and 20d and corresponding tab portions 20a' and 20d' unchanged. With this arrangement, it can be seen in Figure 9B that when installed, wall box 10 is more deeply recessed in wall 40 than in Figure 8B, and thus protrudes less from wall 30 40. Figure 9C shows this more clearly. In this view, it can be seen how tab portions 20a and 20d have been left unchanged, with the mounting surfaces being provided by tab portions 20b and 20c in side 12 and corresponding tab portions in side 14. 8 A particular advantage of providing a two-level or two-depth option is that it provides the installer with different options as to methods of installation. Some installers prefer to secure the wall box to beams or struts within the wall, and then to 5 add a further layer by way of plaster, gypsum or other finish. In this case, the installer will select the set defined by tab portions 20a and 20d as shown in Figure 8C. This provides additional space to add the additional wall layer. Alternatively the tabs 20a and 20b could be manufactured a distance apart such that 0 the final installed depth is the same giving the installer options as to when the wall box can be installed during the building process. Figure 10A shows this application in more detail. Shown there is wall box 10 with tabs 20a, 20d, 20a' and 20d' deployed to be secured directly to timber stud work or 5 metal framework 50 by, for example, screwing with screw 60. In this application, the installer would then place a section of plaster board or gypsum (not shown in this Figure) to cover the studs or framework and tabs 20a, 20d, 20a'and 20d'. This may be known as the 'first fix' arrangement. 0 Other installers will prefer to mount the wall box 10 after the plaster, gypsum or other layer has been added. In this case, the installer will deploy the set defined by tab portions 20b and 20c, as shown in Figure 9C. Figure 10B also shows this application in more detail, in which plaster or gypsum 45 has already been laid over the top of timber or metal framework 50, and wall box 10 is then attached directly to 25 the second layer 45 by screws 60. In this case, tabs 20b, 20c, 20b' and 20c' are used. This may be known as the 'second fix' arrangement. This additional layer 45 may in some cases actually form wall 40 as shown in previous Figures, or may form a base on which further layers may be added to form 30 wall 40. 9 In some forms, there could also be provided an escutcheon 16 (see Figure 10C) which could be used to cover tabs 20b, 20c, 20b' and 20c'. This could also in some cases be accomplished by a door (not shown) of the wall box 10. 5 Figure 11 shows a top cross-sectional view of the arrangements of both Figures 10A and 10B to further illustrate the differences between the two installation methods. In Figure 11 there is shown stud or metal framework 50 and wall box 10 in general. From this view, side 11 of wall box 10 is visible. On the left hand side of Figure 11 is 0 shown the arrangement of the 'first fix' method, in which tab 20b' (and corresponding tabs) is secured directly to stud or metal framework 50. A further layer 45 such as plaster board or gypsum is then applied to cover the tabs used in this arrangement. 5 On the right hand side of Figure 11 is shown the 'second fix' arrangement, in which the plaster or gypsum layer 45 is first attached to the timber or metal framework 50 and then wall box 10 is secured to this layer 45 via tab 20a and corresponding tabs. As shown in Figure 10C above, escutcheon 16 may then be applied to cover any gap 0 between layer 45 and box 10 in the case of the 'first fix' method, or the tabs in the case of the 'second fix' method. In this view, a door 17 is also provided. It will be noted that in these applications, the tabs at varying depths allows the wall box 10 to be mounted at the same level, regardless of the installation method used. 25 This is an alternative use of the tabs to that of being able to vary the depth of installation of wall box 10 as described in relation to Figures 8A-8C and 9A-9C. A further variation is also possible as shown in Figure 12. In this variation, the tabs are able to be bent outwards or inwards about a different axis to provide a mounting 30 surface parallel to the top 11 and bottom 13 sides of wall box 10. In Figure 12, tab 20a is bent outwards and may be used simply as a means of setting a depth for wall box 10, or may even be used to secure wall box 10 to a stud for example, that ends, or has 10 a portion of which, ends some distance along the vertical sides of wall box 10. In Figure 12, both uses are shown. On one side, tab 20a is used to set a depth of mounting of wall box 10. In this use, wall box 10 may be secured to stud 50 and 50' by means of a screw 60 through the sides 12 and 14 of wall box 10. In the other use, 5 tab 20a' is used to secure wall box 10 into the top of a portion of stud 50' with screw 60' applied vertically. It is of course also possible to provide additional levels, as shown in Figure 13. In this example, wall box 10 has three sets of tab portions to provide three optional depths 0 of recess for wall box 10. In Figure 13, the first set is defined by tab portions 20a and 20f, the second set by tab portions 20b and 20e and the third set by tab portions 20c and 20d. Corresponding tab portions 20a' to 20f' are also provided on opposite wall 14. This arrangement provides even more flexibility for even greater applications. Of course, any number of levels or depths may be provided as required. 15 Figure 14 shows an example of the electrical safety requirements for the present invention. Electrical installation shall be performed by a qualified and licensed electrician, in accordance with Australian Standard AS/ NZS 3000. The socket outlet must be protected by an over-current protective device (eg. MCB). The position of the 10 product label is shown as 100. The maximum load of the twin-switched sockets (as supplied with the enclosure) shall not exceed 10A at 240V/5OHz as stated on the product label. The Insulated Terminal Bar 70 may be used as TRC or each bonding bar and should be wired in accordance with AS/ACIF S009. There is a provision for earthing the enclosure 80, such as a connection from CET to enclosure earth terminal. 25 This is to be wired in accordance with AS/ACIF S009. The mains power outlet wiring shall only terminate to the mains outlet socket 90. Telecommunications cabling shall be performed by a qualified and licensed installer, in accordance with Australian Standard AS/ACIF S009. Only patch leads routing 30 changes are allowed by non-licensed personnel. 11 Depending on access to the key for the lockable cabinet access door, the cabinet will meet the requirements of a "service access area" or a "restricted access area" or an "operator access area". The cabinet must be kept locked and access only granted to appropriate persons deemed necessary according to the access requirements of the 5 type of equipment installed within the enclosure. Figures 15A-C show one example of possible installation instructions for studwork spacing and cabling paths required for the flush mount of the present invention. The studwork needs to be between 465 and 470mm apart for mounting (Fig. 15A). Data .0 cables are cabled to the left hand side of the cavity and coaxial cables are cabled to the right hand side of the cavity as shown by Fig. 15B. Note that the C-section black rubber extrusion (as supplied) must be fitted to all metal edges that come in contact with the cables. Power is run on the opposite side of the studwork on the left hand side and brought through the stud underneath the enclosure. A hole is required, [5 20mm to the right of the stud and 10mm in from the front of the noggin for the power cable, as shown in Fig. 15C. One example of a method of installation of the flush mounted wall box is shown in Figs. 16 and 17. Push the 6 "first fix" tabs outwards with a thumb or finger or lever 20 the edge of the tab with a flat screwdriver. Then bend the tabs with either a thumb and finger or with a pair of pliers across the holes keeping the tab flat. Fix the enclosure into place using bugle head screws into timberwork or metal cutting screws into steel framework. 25 A further example of a method of installation of the flush mounted wall box may include cutting out the required 465 to 470mm wide by 900 to 905mm high are from the plasterboard (Fig. 18). Push the 6 "second fix" tabs outwards with a thumb or finger, or lever the edge of the tab with a flat screwdriver. Then bend the tabs with either a thumb and finger or with a pair of pliers across the holes keeping the tab flat 30 (Fig. 19). First introduce the co-axial, telephone and data cables, then introduce the power cable through the cable entry points as shown in Figs. 20 and 21. Fix 11a enclosures into place using bugle screws into timberwork or metal cutting screws into steel framework (Fig. 22). Figure 23 illustrates an example of a method of fitment of the Keystones. Bezels may 5 be removed temporarily by pinching the plastic spigot legs together that protrude through the escutcheon. Tear off foam along perforations as required and re-fit. To re-refit bezels, simply align spigots to holes and push bezels back into the escutcheon. .0 A door can be hinged on the right hand side of a wall box. An example of instructions for this are as follows: 1. Remove door; 2. Remove escutcheon; 3. Knock out form in escutcheon for clearance to door key barrel (Fig. 24); [5 4. Bend up lock tab on escutcheon (Fig. 25); 5. Re-fit escutcheon; 6. Remove paint masking discs (top and bottom) (Fig 26); and 7. Latch door into new position. 20 It will be understood that the above has been described with reference to particular embodiments and that many variations and modifications may be made within the scopes of the different aspects of the present invention. Throughout the specification and the claims that follow, unless the context requires 25 otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers. The reference to any prior art in this specification is not, and should not be taken as, 30 an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge. 11b

Claims (14)

1. A wall box including a plurality of sides defining a front and a rear, wherein at least one of the plurality of sides includes an integral tab portion located within the boundary of the respective side which in use, is able to be bent outwards to 5 provide a mounting surface for mounting to a support.

2. A wall box as claimed in claim 1 wherein at least two sides have at least one integral tab portion. 0

3. A wall box as claimed in claim 1 or 2 wherein all sides have at least one integral tab portion.

4. A wall box as claimed in any one of claims 1 to 3 wherein at least one side has a plurality of integral tab portions. 5

5. A wall box as claimed in claim 4 wherein the plurality of integral tab portions are disposed at different depths on the at least one side.

6. A wall box as claimed in claim 4 , wherein the plurality of integral tab portions 0 are arranged in a plurality of sets of integral tab portions, each set comprising one or more integral tab portions each located within the boundary of the respective side and each set being disposed at a different depth of the at least one of the plurality of sides. 25

7. A method of mounting to a wall a wall box as claimed in any one of claims 1 to 6, the method including: bending at least one of the integral tab portions away from the at least one of the plurality of sides to provide a mounting surface; and securing the mounting surface to a support associated with the wall. 30

8. A method as claimed in claim 7 wherein the support associated with the wall is a stud. 12

9. A method as claimed in claim 7 wherein the support associated with the wall is the wall. 5

10. A method as claimed in claim 7, further including: determining a mounting depth at which the wall box will be mounted within the wall; selecting at least one integral tab portion disposed at an appropriate depth for the determined mounting depth; 0 bending the selected at least one integral tab portion outwards to provide the mounting surface; and securing the mounting surface to a support associated with the wall.

11. A wall box as claimed in claim 1 substantially as herein described with reference 5 to the accompanying drawings.

12. A method as claimed in claim 7 substantially as herein described with reference to the accompanying drawings. 0

13. A wall box substantially as herein described with reference to the accompanying drawings.

14. A method of mounting to a wall a wall box, substantially as herein described with reference to the accompanying drawings. 25 13